Front Drive Shaft
FRONT DRIVE SHAFTComponents:
REMOVAL
1. REMOVE FRONT WHEEL
2. REMOVE ENGINE UNDER COVER
3. DRAIN DIFFERENTIAL OIL
4. REMOVE DRIVE SHAFT LOCK NUT
a. Using a screwdriver and hammer, remove the grease cap.
b. Remove the cotter pin and lock cap.
c. While applying the brakes, remove the lock nut.
5. DISCONNECT FRONT SUSPENSION NO. 1 LOWER ARM
a. Remove the cotter pin and nut.
b. Using SST, disconnect the lower suspension arm from the lower ball joint.
SST 09628-62011
6. DISCONNECT FRONT DRIVE SHAFT
a. Using a plastic hammer, disengage the drive shaft from the axle hub.
b. Push the steering knuckle outward and disconnect the drive shaft from the steering knuckle.
NOTICE: Be careful not to damage the oil seal, boots and dust seal.
7. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for LH Side).
8. REMOVE FRONT DRIVE SHAFT ASSEMBLY
a. RH drive shaft: Using a brass bar and hammer, remove the RH drive shaft.
NOTICE: Be careful not to damage the dust cover and oil seal.
b. LH drive shaft: Using SST, remove the LH drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE: Be careful not to damage the dust cover and oil seal.
c. Using a screwdriver, remove the snap ring from the inboard joint shaft.
DISASSEMBLY
1. INSPECT FRONT DRIVE SHAFT ASSEMBLY
a. Check to see that there is no remarkable play in the outboard joint.
b. Check to see that the inboard joint slides smoothly in the thrust direction.
c. Check to see that there is no remarkable play in the radial direction of the inboard joint.
d. Check the boots for damage.
2. REMOVE OUTBOARD JOINT BOOT CLAMP
a. Using pliers, pinch the claws to compress the large inboard joint boot clamp and remove it.
b. Using a side cutter, cut the small inboard joint boot clamp and remove it.
c. Using a side cutter, cut the 2 outboard joint boot clamps and remove them.
3. REMOVE INBOARD JOINT BOOT CLAMP
a. Using pliers, pinch the claws to compress the large inboard joint boot clamp and remove it.
b. Using a side cutter, cut the small inboard joint boot clamp and remove it.
c. Using a side cutter, cut the 2 outboard joint boot clamps and remove them.
4. REMOVE FRONT DRIVE INBOARD JOINT
a. Place matchmarks on the inboard and outboard joint shafts.
NOTICE: Do not punch the marks.
b. Using a snap ring expander, pull out the outboard joint shaft while expanding the snap ring.
5. REMOVE FRONT DRIVE SHAFT INBOARD JOINT BOOT
6. REMOVE OUTBOARD JOINT BOOT
7. REMOVE FRONT AXLE HUB DUST SEAL
a. Using SST and a press, remove the dust seal.
SST 09950-00020
8. REMOVE FRONT DRIVE SHAFT DUST COVER
a. Using SST and a press, remove the dust cover.
SST 09950-00020
REASSEMBLY
1. INSTALL FRONT DRIVE SHAFT DUST COVER
a. Using a screwdriver and hammer, install a new dust cover.
2. INSTALL FRONT AXLE DUST SEAL
a. Using a screwdriver and hammer, install a new dust seal.
3. TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND BOOT CLAMPS
HINT:
- Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from bearing damaged.
- Before installing the boots, place 3 new clamps to the small boot ends and large boot end (outboard joint side).
4. INSTALL FRONT DRIVE INBOARD JOINT
a. Align the matchmarks placed before disassembly, and using a snap ring expander, put in the inboard joint shaft while expanding the snap ring.
5. INSTALL BOOT TO FRONT DRIVE OUTBOARD JOINT SHAFT
a. Before assembling the boot, pack the outboard joint and boot with grease in the boot kit.
Grease capacity (Color = Black): 205 - 225 g (7.23 - 7.94 oz.)
6. INSTALL BOOT TO FRONT DRIVE INBOARD JOINT
a. Pack the inboard joint and boot with grease in the boot kit.
Grease capacity (Color = Black): 190 - 210 g (6.70 - 7.41 oz.)
b. Temporarily install the boot to the inboard joint shaft.
7. CHECK FRONT DRIVE SHAFT LENGTH
a. Make sure that the 2 boots are on the shaft groove.
b. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length.
Drive shaft standard length: 523.5 ± 2.0 mm (20.610 ± 0.079 inch)
8. INSTALL LARGE INBOARD JOINT BOOT CLAMP TO INBOARD JOINT BOOT
a. Place the large inboard joint boot clamp.
b. Using pliers, compress the clamp and attach the claws.
9. INSTALL OTHER BOOT CLAMP TO BOTH BOOTS
SST 09521-24010
a. Secure the clamp onto the boot.
b. Place SST onto the clamp.
SST 09521-24010
c. Tighten the SST so that the clamp is pinched.
NOTICE: Do not overtighten the SST.
d. Using SST, adjust the clearance of the clamp.
SST 09240-00020
Clearance: 1.0 - 1.5 mm (0.039- 0.059 inch)
10. INSPECT FRONT DRIVE SHAFT
INSTALLATION
1. INSTALL FRONT DRIVE SHAFT
a. Install a new snap ring to the inboard joint shaft.
b. Apply gear oil to the inboard joint shaft and differential case sliding surface.
c. Set the snap ring with opening side facing downward.
d. Using a brass bar and hammer, install the drive shaft.
NOTICE: Be careful not to damage the dust cover and oil seal.
HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feeling when driving.
e. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in the axial direction.
f. Check that the drive shaft cannot be removed by hand.
2. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for LH Side).
3. CONNECT FRONT DRIVE SHAFT
NOTICE: Be careful not to damage the oil seal, boots and dust seal.
4. CONNECT FRONT SUSPENSION NO. 1 LOWER ARM
a. Connect the lower suspension arm to the lower ball joint.
b. Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
HINT: Face the hole for the cotter pin forward.
Torque: 140 Nm (1,450 kgf-cm, 103 ft. lbs.)
5. INSTALL FRONT DRIVE SHAFT LOCK NUT
a. While applying brakes, install the nut.
Torque: 235 Nm (2,400 kgf-cm, 173 ft. lbs.)
b. Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60°.
6. FILL DIFFERENTIAL OIL
7. INSTALL ENGINE UNDER COVER
8. INSTALL FRONT WHEEL
Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.)